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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 07 | July 2020 www.irjet.net p-ISSN: 2395-0072
Arc Furnace Load Harmonics Minimization using Shunt Passive Filters.
Ekramy S. Mahmoud1, Hilmy Awad2, Wael Rady3, Mostafa ELshnawey4
1Assistant Professor at Pyramids High Institute for Engineering and Technology, Cairo, Egypt 2Assistant Professor at Electrical Technology Dept., Faculty of Industrial Education, Helwan University,
Cairo, Egypt 3Professor of Curricula and Instruction Methods, Faculty of Education, Helwan University, Cairo, Egypt
4Researcher at Electrical Technology Dept., Faculty of Industrial Education, Helwan University, Cairo, Egypt ---------------------------------------------------------------------***----------------------------------------------------------------------Abstract – The main objective of this paper is to determine the harmonics in the Arab Steel Company (Arco Steel) in Sadat City, Egypt. A Power Quality Analyzer device has been installed at the point of common coupling (PCC) and the data has been recorded during one month. The main loads of the station are: Electric Arc Furnace (EAF) and Ladle Refining Furnaces. Due to the presence of harmonics, the loads were disturbed, and few problems were recorded such as incorrect operation of devices, premature ageing of equipment, and additional power losses in addition to overvoltage and overcurrent. In order to mitigate the generated harmonics, Harmonics will be considered in this paper; a real distributed nonlinear load will be studied which produce sever harmonics. Passive filters will be designed to mitigate harmonics and keep it at the standard limits. The plant was modelled in MATLAB/SIMULINK using the measured data and then passive filters are designed to fulfil the standard limits.
Key Words: Electric Arc Furnace, Harmonics, Nonlinear load, Passive Filter, Power quality, Point of Common coupling.
1. INTRODUCTION The amazing and rapid progress in electronic applications has
increased the sensitivity of devices and equipment to any
deviations in the input voltage of these loads. Hence, the
science of Power Quality (PQ) has come to light since 1967 [1].
PQ is defined as “The concept of powering and grounding
sensitive equipment in a manner that is suitable to the
operation of that equipment” [2, 3]. Voltage dips, voltage
swells, transients, harmonics, unbalance, flicker and many
other issues are recorded in the literature to cause significant
loss in production for sensitive loads such as cement factories
[4], textile factories [5], chemical and petrochemical stations
[6], and mining industries [7].
In many cases, harmonics were reported to have adverse
effects on industrial loads as well as the utility equipment [8,
9]. Harmonics are defined as: “A sinusoidal component of a
periodic wave or quantity having a frequency that is an
integral multiple of the fundamental frequency” [10]. For
instance, Fig. 1 shows the 3rd, 5th, and the 7th harmonics for a
generic fundamental waveform with a period of T seconds.
Fig -1: Sinusoidal generic waveform and its 3rd, 5th and 7th
harmonic.
The main cause of harmonics is the existence of nonlinear
loads such as power electronics-based loads. These include
(but not limited to) AC motor drives, DC motor drives,
Programmable-logic controllers and other controlled
industrial process [11, 12]. Other system equipment may
generate harmonics such as generators and transformers. In
principle, the loads are the responsible for producing current
harmonics which in turn most probably would produce
voltage harmonics. On the other hand, the utility may produce
voltage harmonics which in turn produces voltage harmonics
at the load terminals. Due to the nonlinearity nature of most of
the loads, voltage harmonics are normally different from
current harmonics [13]. However, both voltage and current
harmonics must be investigated in all cases.
One of the heavy nonlinear loads is the electric arc furnace
which gives rise to harmonics. The arc furnace is characterized
by time-varying, distributed and noisy parameters [14], which
causes the generated harmonics to exceed the IEEE Standard
519-1992 [15, 16]. Generation of harmonics in the case of arc
furnace is attributed to the non-linear voltage-current
characteristic and the change of the arc length during the
melting of the process [17]. In [18], individual harmonics were
reported where the 5th and the 11th current harmonics were
the most significant, 33.6 and 8.7 %, respectively.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 07 | July 2020 www.irjet.net p-ISSN: 2395-0072
The Egyptian Steel Company load is the case study in this
paper where presents the measurements of harmonics were
done for a one-month duration.
2. Simulation of the source and load using matlab-simulink Electric Arc Furnace (EAF) is the most difficult load type in electrical distribution system. Electric arc furnaces are used for melting high melting point alloys such as steels as show in fig 2. In these furnaces, electric energy is used to form an electric arc which heats the metal by the radiant heat evolved. Heat is generated by electric arcs and in most types of furnaces also by resisting heating in the charge as the current passes from one arc to another. The basic of electrical operation of arc furnaces is the optimum current for the selected voltages or lower current as required by the power factor. Electric arc furnaces have founded wide applications in the steel industry for refining and making alloy steels and in the production of alloy [19].
Disturbances produces in electrical networks by electric arc furnaces can significantly affect the voltage quality supplied by electrical power companies.
.
Fig -1: Electric Arc Furnace.
Substation which connected with the network to supply Arc furnace load (Arco-steel company). There are 4- high voltage power circuits (220 k v). Fig 3 shows the single line diagram where the main source for loads are two power transformer, one of them feeds high nonlinear load (Arc furnace load), this load dived into two main load, EAF (Electrical arc furnace) and LRF (Ladle Refining Furnaces) of the transformer feed utility loads.
Fig -3: single line diagram for Distributed system with
loads.
Fig -4: nonlinear load fed from power transformer.
Figure 4 represents a real practical load which located at
Sadat city (Arab company for special steel). This load is Arc
furnace load. This type of load can cause many power quality
problems such as voltage sag, transient, harmonics,……etc,
harmonic problem will be studied. Figure 4 shows nonlinear
load fed from power transformer through underground cable.
Power harmonic analyzer is used to measure these problems.
Power Quality Analyzer device is used to the measure of
harmonics which are recorded in table 1. Referring to this
table, the considered load causes big power quality problem
which produce each of odd and even harmonic, Also, it can be
observed that the value of 5th harmonic exceeds the
fundamental, in addition many individual harmonics are
generated and exceed the standard limits.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 07 | July 2020 www.irjet.net p-ISSN: 2395-0072
Referring to figure 5, the internal impedance of the power
transformer can be represented as inductive reactance cable
can be represented π connection which its parameters (L, C).
The considered underground sheet L=.118mh, C=. 318µf,
R=.113Ω.
Fig -6: current waveform of the system without load.
Figure 6 shows the current waveform of the system without
load, fundamental Waveform is the sinusoidal waveform that
has the supply Frequency.
Fig -7: the system simulation considering nonlinear load.
Figure 7. shows a simulation of the studied network after connecting the considered arc furnace load. Referring to figure 7, the considered nonlinear load can be simulated as several current sources at different frequencies.
Figure 8 shows The current wave form at the pcc without filters. When EAF load is connected with the system at the pcc, highly distortion in current wave form is occurred. Fig 8 shoes the distortion in current waveform, this figure can be obtaining from Mat lab simulation shown in fig 8.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 07 | July 2020 www.irjet.net p-ISSN: 2395-0072
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